Posted 04 January 2022

At the conclusion of my last post on this subject, I had refurbished the charging station IR transmit subsytem with a new perfboard setup to replace the ugly terminal strip implementation. The next step in ‘bringing up Wall-E3’ is to verify IR Homing functionality. The IR transmitter is modulated by a very stable 520.8Hz square wave produced by the Teensy 3.2 waveform generator, and this signal is demodulated by a Teensy 3.2 on the robot (see this post for the details). This technique has been working for years with the Wall-E2 robot, and since I simply moved the entire IR homing subsystem from Wall-E2 to Wall-E3, I have some hopes that it will work correctly (fingers crossed!). Here’s the test setup:

The first step was just to verify that both phototransistors were receiving the IR signal, as shown in the scope photo below:

At this point I also verified that rotating the robot caused the left and right detector signals to vary appropriately, so that all works. The next step is to verify that the demodulator output still behaves properly. To do this, I ported the appropriate code from my Wall-E2 project into T35_WallE3_V4.

06 January 2022 Update:

When attempting to verify IR Demodulator output from the onboard Teensy 3.2, all I got was zeros across the board. After investigating some more, I came to the conclusion that the main Teensy 3.5 was for some reason unable to even talk to the IR Demod Teensy via I2C. After the usual amount of fumbling around and searching the Teensy forum, I began to think that the problem was caused by the lack of proper pullup resistors on the I2C bus connecting the two. In the case of Wall-E2, I had pullup resistors mounted on the Wixel shield board, but this did not get transferred over to Wall-E3. I was also misdirected a bit by the IC2_PULLUP_INT defined value for Wire.begin calls – this, at least in my mind, implied that the internal pullups available in the ARM processor would work with two Teensy processors – apparently not. So, in order to run this issue down, I created a small test bed consisting of a T3.5 ‘master’ and a T3.2 ‘slave on a plug-in board as shown below:

Then I loaded the ‘Basic_Master’ and ‘Basic_Slave’ i2c_t3 library sketches and verified that the master and slave were communicating properly. Then I removed the pullups and changed the ‘Wire.begin()’ statements to use I2C_PULLUP_INT to see if they would still communicate – and, contrary to some posts on the Teensy Forum they did! I grabbed some scope photos of the SDA & SCL lines with and without external 2.2K pullups, as follows:

As can be seen from the above photos, there is no perceivable difference between the waveforms for the ‘with’ and ‘without’ external pullups cases. So, for at least this very simple Teensy-to-Teensy case, pullups don’t appear to be required.

Next, I changed the configuration to replace the ‘Slave’ T3.2 with the T3.2 mounted on the IR detector housing, as shown below:

Then I loaded T35_WallE3_V4 onto the ‘master’ T3.5 and re-ran the experiment. This time the T3.5 detected the T3.2 and produced valid output, as shown below:

As can be seen from the above, the computed ‘IRHomingValTotalAvg’ value varies with the alignment of the IR transmitter module. Moreover, since this value is computed using the N-path bandpass filter algorithm implemented earlier, it also verifies that the code is running properly on the IR detection/homing module, as well as the corresponding code in the main controller Teensy 3.5. Yay!

While the above validates the T3.5 main controller and the I2C bus between it and the T3.2 IR Demodulator module, it doesn’t explain why it didn’t work on the actual robot. The only difference between the configuration tested above and the configuration on Wall-E4 is the presence of the MPU6050 module on the same I2C bus. So, I added this piece back into the circuit as shown below:

With this configuration, the main controller failed to connect to the IR demod module, just as it did on Wall-E3. So, at least the failure is consistent with previous work. To further investigate, I looked at the I2C bus waveforms with and without the MPU6050 module on the bus, as shown below:

After some more head-scratching, I finally narrowed the issue down to the double-layer connector on the MPU6050 module, where I found not just one, but two bad solder connections – oops! After repairing the connections, I reran the test with the MPU6050 on the I2C bus, and this time I got the proper behavior; case closed, and it only cost me most of a day! 🙁

07 January 2022 Update:

I re-installed the IR Homing/MPU6050 subsystem on Wall-E3 and verified proper operation. Next step will be to try some homing experiments.

Stay tuned,

Frank